Orifice sealing physical barrier

ABSTRACT

A physical barrier for sealing an orifice in a panel member is presented. The physical barrier includes a carrier that has one or more locating pins mounted on it. The pins are adapted to locate the carrier in the orifice. The physical barrier also includes a sealing material attached to the carrier. Also included is a method of installing the physical barrier into an orifice of a panel member.

This application is a continuation of U.S. application Ser. No.09/992,502, filed Nov. 19, 2001, now U. S. Pat. No. 6,691,468.

FIELD OF THE INVENTION

This invention relates to devices and methods for sealing orifices inpanel members.

BACKGROUND OF THE INVENTION

Physical barriers are commonly used to seal orifices in certain objects,such as panel members in motor vehicles, buildings, householdappliances, etc. These barriers normally are used to prevent physicalmaterials, fluids, and gases, such as environmental contaminants, fumes,dirt, dust, moisture, water, etc., from passing through the orifice. Forexample, an automotive panel, such as a door panel, typically hasseveral orifices in the sheet metal, which are created for variousreasons during manufacturing. Further, various structural components ofautomobile bodies have a variety of orifices, hollow posts, cavities,passages and openings that can allow contaminants into the passengercompartment. These holes, orifices, and cavities are typicallybarricaded with duct tape, butyl-based plastic patches, and sealingplugs made from foam, rubber, or some other material. Another knownphysical barrier for cavities involves introducing a foam product or afiberglass matting to fill in the cavity.

Known barriers, however, are unsatisfactory for a variety of reasons.Sealing plugs, which were a step forward over other barriers, utilizesnap-fit clips to hold the plug in place, i.e., in an orifice of a panelmember. However, snap-fit clips on a sealing plug, without more, areinsufficient because the clips cannot produce a contaminant-tight sealbetween the plug and the panel member. To overcome this, a sealermaterial, such as compressible rubber, adhesive, caulk or mastic, hasbeen used in combination with a carrier to form the sealing plug. Thesealer material may create a contaminant-tight seal between the carrierand the panel member.

With the introduction of the sealer material, however, new drawbacksarise. Often the sealer material needs to be activated in order to forma contaminant tight seal. Such activation may be in the form of mixingtwo components together or physical kneading of the material. This canbe labor intensive, as well as placing a time limit on the installationprocess because the barrier must be placed in the orifice during therelatively limited active period of the sealer material. Furthermore,known sealer materials have not been able to protect against prolongedexposure to contaminants, but only against intermittent exposure tocontaminants. This is a particular problem with respect to water.

Installation of known snap-fit barriers has also been problematicbecause installation of such barriers exactly in the center of theorifice has been difficult. Once the barrier is placed askew in theorifice, the presence of the sealer material prevents the barrier fromcentering itself. For the same reason, it is also difficult for theinstaller to center the barrier.

This skewed or off-center installation of the barrier creates twoproblems. First, it places unequal strain on the snap-fit clips thathold the barrier in place. This tends to lead to failure of one or moreof the clips, which results in a leaky seal. To overcome this type offailure, stiffer snap-fit clips, which require more force to flex, arerequired. This in turn increases the force needed to install the barrierinto the orifice to such a degree that a person cannot performinstallation without mechanical assistance. Thus, force-multiplyingtools or machines are required to install the barrier. The use of toolsor machines to install these barriers increases the complexity and costof the installation process beyond that which is economical.

Second, off-center installation increases the number of failed seals.Known sealer materials cannot compensate for off-center installation.Off-center installation can lead to gaps between the panel member andthe carrier that are not filled by the sealer material. Thus, the sizeof the barrier must be closely matched to the size of the orifice toensure that there are no gaps between the carrier and the panel member.Therefore, expensive precision manufacturing techniques are required inthe formation of the orifice and the carrier to ensure that the barriercannot be installed incorrectly, i.e., off-center.

Consequently, the inventor hereof has recognized a need for a physicalbarrier that overcomes one or more of these problems.

SUMMARY OF THE INVENTION

The present invention is a physical barrier for sealing an orifice in apanel member. The physical barrier includes a carrier that has one ormore locating pins mounted on it. The pins are adapted to located thecarrier in the orifice. The physical barrier also includes a sealingmaterial attached to the carrier. The present invention also includes amethod of installing the physical barrier into an orifice of a panelmember.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 shows a perspective view of a physical barrier of the presentinvention as it is being installed into a panel member with an orifice.

FIG. 2 shows a perspective view of a carrier with a sealer material of aphysical barrier according to the present invention.

FIG. 3 shows a cross-section of a snap-fit clip used in a preferredembodiment of the present invention.

FIG. 4 shows a cross-section of a guide pin used in a preferredembodiment of the present invention.

DETAILED DESCRIPTION

As seen in FIG. 1, a panel member 2 includes an orifice 4. Orifice 4 hasa perimeter where panel member 2 ends and orifice 4 begins. Orifice 4receives a physical barrier 10 that includes a carrier 12 and sealermaterial 14. As seen more clearly in FIG. 2, attached near the edge ofcarrier 12 are generally flexible snap-fit clips 16 and generally rigidlocating pins 18. Clips 16 and pins 18 are roughly perpendicular to themain body 20 of carrier 12. Pins 18 maybe taller than or equal in heightto clips 16.

Carrier 12 may also include a wall 22, which may be set to the interiorof clips 16 and pins 18. Carrier 12 may also include one or more ribs24, which help give main body 20 structural stiffness. In one usefulembodiment, a rib 24 is placed such that a pin 18 is located near eitherend of the rib, as shown in FIG. 2.

Carrier 12 also includes a lip 26 that defines the perimeter of carrier12. The perimeter defined by lip 26 is larger than the perimeter oforifice 4. Lip 26 is set to the exterior of clips 16 and pins 18. Lip 26may be continuous around the entire perimeter of the carrier or lip 26may have one or more discontinuities 27. Discontinuities 27 may be useto introduce sealer material 14 onto carrier 12.

As best seen in FIG. 3, each clip 16 has a peak 28. These clip peaks 28,when taken as a group, generally define a shape that will fit insideorifice 4. Put another way, peaks 28 define a perimeter, called a clippeak perimeter, which is smaller than the orifice perimeter. In thisway, all peaks 28 will be easily insertable into orifice 4 duringinstallation.

On its body 30, each clip has a clip face 32. These faces 32, when takenas a group, generally define a clip face perimeter that is slightlylarger than the clip peak perimeter, and the same size or smaller thanthe orifice perimeter. Thus, clip faces 32 may or may not abut panelmember 2 when physical barrier 10 is properly installed.

Between peak 28 and clip face 32, each clip 16 has a wedge shaped head34. Head 34 faces lip 26 as opposed to wall 22 and causes body 30 ofclip 16 to flex as carrier 12 is installed into orifice 4. Head 34prevents the incidental displacement of carrier 12. The distance betweenhead 34 and carrier 12 is at least the lip height 36 plus the thicknessof panel member 2. Other suitably shaped snap-fit clips may also be usedin the present invention.

As best seen in FIG. 4, each pin 18 has a peak 38. These pin peaks 38,when taken as a group, generally define a shape that will fit insideorifice 4. Put another way, peaks 38 define a pin peak perimeter that issmaller than the orifice perimeter. In this way, all pin peaks 38 willbe easily insertable into orifice 4 during installation.

Between peak 38 and a base 40, each pin 18 has a guiding surface 42. Atbase 40, guiding surfaces 42, when taken as a group, define a baseperimeter which is the same size as the orifice perimeter. Guidingsurfaces 42 face lip 26 as opposed to wall 22. Thus, the base perimeteris larger or the same size as the clip face perimeter of clips 16 suchthat guiding surfaces 42 abut panel member 2 when physical barrier 10 isproperly installed. Pins 18 make a smooth transition from peak 38 tobase 40. Thus, the peak perimeter of pins 18 is smaller than the baseperimeter of pins 18.

Clips 16 and pins 18 align so as to mimic the shape of orifice 4. Forexample, if orifice 4 has a straight portion, then clips 16 and pins 18form a straight line. If orifice 4 has an arcuate portion, then clipsand pins 18 form an arc that has the same curvature as the orifice.

Clips 16 and pins 18 may be arranged in a generally alternating patternsuch that one pin is located between a pair of clips. Preferably, tosecurely hold barrier 10 in place, an equal number of clips 16 and pins18 are utilized. Each pin 18 may be associated with two clips 16; one onits “right” and one on its “left,” where right and left are relative.The number of clips and pins on a carrier may be chosen based on thesize and shape of the orifice, as well as the desired amount ofredundancy in clips to ensure that failure of one or more clips does notcompromise the physical barrier. For round orifices, an alternatingarrangement of clips and pins may be sufficient. For polygonal orifices,a pair of pins and a clip per side may be sufficient. This configurationis illustrated in FIG. 2.

In an alternate embodiment, one or more pins 18 may locate carrier 12 bybeing received in an receptacle adjacent to or near orifice 4. In thisembodiment, seating the pin in the receptacle properly locates thecarrier within the orifice.

The spacing between clips 16 and pins 18 is not critical, however, it ispreferred that clips 16 and pins 18 are equally distributed along theperimeter of carrier 12 for round orifices or along the sides of thecarrier for polygonal orifices.

Sealer material 14 is preferably located between clips 16 and wall 22,but may be located all around clips 16. Also, sealer material 14 ispreferably located between pins 18 and wall 22, between pins 18 and lip26, and under pins 18. However, sealer material 14 may also be utilizedin less than all of these locations.

The sealer material 14 of barrier 10 may be any known sealing material,but preferably one that expands upon activation. One useful type ofexpandable material is a heat activated foam. While a heat activatedfoam is preferred, it is to be understood that the invention may bepracticed with other types of foams which are, for example, chemicallyactivated. While the use of clips 16 is preferred, the present inventioncould also be implemented without clips 16 where sealer material 14adhesively attaches carrier 12 to panel member 2.

The use of the present invention is now described. Barrier 10 isinserted into orifice 4. Because the perimeter of carrier 12 is largerthan the orifice perimeter, lip 26 ensures that carrier 12 is not overinserted into orifice 4. Pins 18 insure that carrier 12 is centered andnot twisted.

Specifically, since pins 18 are rigid, as barrier 10 is inserted intoorifice 4, guiding surfaces 42 of pins 18 guide carrier 12 to the centerof orifice 4. Only after carrier 12 is mostly centered are bodies 30 ofclips 16 required to flex. Carrier 12 is then seated such that guidingsurfaces 42 at base 40 of pins 18 abut panel member 2. Depending on theclip face perimeter, clip faces 32 may also abut panel member 2.

By centering carrier 12, the maximum amount of strain all clips 16 haveto endure is significantly reduced. This reduces the strength of clips16 that are needed to properly install barrier 10, which in turn reducesthe amount of force needed to install barrier 10. Thus,force-multiplying tools or machines are not needed to install thebarriers of the present invention.

The alternating arrangement of clips 16 and pins 18 also helps reducethe amount of strain clips 16 have to endure. By placing at least onepin 18 on either side of clip 16, the carrier 12 is prevented from beinginstalled in a twisted manner. Namely, clips 16 will never engage panelmember 2 without guiding surfaces 42 of the two adjacent pins 18 alsoengaging panel member 2. The simultaneous engagement of guiding surfaces42 and clips 16 prevents undue strain on clips 16. Because the clip andpin peak perimeters are smaller than the orifice perimeter, all clips 16and pins 18 are insertable into orifice 4. Furthermore, because pins 18are taller than clips 16, pins 18 enter orifice 4 first duringinstallation, thus assuring that guiding surfaces 42 of pins 18 willcenter barrier 10 in orifice 4.

After carrier 12 is installed, sealer material 14 is activated to createthe seal between carrier 12 and panel member 2. Wall 22 acts as adirectional aid for sealer material 14, such that when sealer material14 is activated, wall 22 helps direct sealer material 14 toward clips 16and pins 18, and thus panel member 2. Expanded sealer material 14adheres carrier 12 to panel member 2 surrounding orifice 4.

The use of expandable foam has several advantages over conventionalsealer materials. Orifice 4 need not be formed using precisionmanufacturing techniques because the expandable foam will fill theavailable space. Any gaps between carrier 12 and panel member 2 will befilled by the expanding foam, thus creating a contaminant tight seal.The expanding foam also allows for a reduced number of sizes of barriersto be produced, because one barrier could be used to block severalclosely sized orifices. Furthermore, the seal produced by the use ofexpandable foam withstands prolonged exposure to contaminants,particularly water.

In this use of expandable foam, imperfect expansion of the foam can betolerated, as can imperfect placement of the foam because as the foamexpands, wall 22 will directs it toward clips 16, pins 18 and panelmember 2 to help ensure a contaminant tight seal.

Heat expandable foams have another advantage when used in the automotiveindustry. Heat expandable foams allow for the elimination of aninstallation step because almost all automobiles have paints or coatingthat are heat dried. This eliminates the need for a separate activationstep to seal the orifice.

Carrier 12 may be made of conventional materials, with the onlyconsideration being the activation conditions for sealer material 14.Thus, carrier 12 must be able to maintain its physical rigidity at theactivation conditions. For example, when using a heat activated sealermaterial, carrier 12 should not melt at temperatures used in the chosenheat source. In the vehicle coating and paint area, the carrier shouldwithstand temperatures normally utilized in the paint and coating dryingovens. While metals may be used, plastics are preferred because of thereduced weight and reduced amount of force needed to install a plasticcarrier as compared to a metal carrier. One useful plastic material isnylon.

While the invention has been specifically described in connection withcertain specific embodiments thereof, it is to be understood that thisis by way of illustration and not of limitation, and the scope of theappended claims should be construed as broadly as the prior art willpermit.

1. A physical barrier for sealing an orifice in a panel member,comprising: a carrier configured to cover the orifice when installed; aplurality of conically-shaped locating pins having sloped guidesurfaces, said locating pins extending from said carrier and configuredto extend into the orifice when said carrier is installed so as tomaintain said carrier substantially centered over the orifice; and asealing material on said carrier configured to seal an interface betweensaid carrier and the panel member when said carrier is installed.
 2. Thephysical barrier of claim 1, further comprising at least one clipmounted to said carrier, which is physically distinct from said locatingpins, configured to secure said carrier over the orifice relative to thepanel member when installed into the orifice.
 3. The physical barrier ofclaim 1, wherein said sealing material is an expandable foam.
 4. Thephysical barrier of claim 1, wherein said sealing material is attachedto an area of said carrier that substantially follows a perimeter ofsaid carrier.
 5. The physical barrier of claim 1, further comprising awall attached substantially perpendicular to said carrier, said wallsubstantially following a perimeter of said carrier, said wall beingpositioned inside of an outermost perimeter of said carrier, so as tocreate a sealer area between said wall and said outermost perimeter ofsaid carrier where said sealer material is attached to said carrierprior to installation.
 6. The physical barrier of claim 5, wherein saidwall is configured to direct said sealing material toward said outermostperimeter of said carrier when said sealing material is activated. 7.The physical barrier of claim 1, further comprising at least oneattachment member mounted to said carrier, which is physically distinctfrom said locating pins, configured to secure said carrier over theorifice relative to the panel when installed into the orifice.
 8. Amethod of sealing an orifice in a panel member, comprising: providing acarrier member having a plurality of conically-shaped locating pins andhaving sloped guide surfaces a sealing material thereon, said locatingpins extending substantially perpendicular from said carrier member;inserting said locating pins into the orifice such that said pluralityof locating pins maintain said carrier member substantially centeredover the orifice when installed; and causing said sealing material toseal an interface between said carrier member and the panel member. 9.The method of claim 8, wherein said locating pins are configured suchthat an outer surface of each locating pin abuts a periphery edge of theorifice when the carrier is installed.
 10. The method of claim 8,wherein said step of causing said sealing material to seal an interfaceincludes activating said sealing material.
 11. The method of claim 10,wherein said sealing material is activated by heating the sealingmaterial.
 12. The method of claim 8, further comprising the step ofengaging a clip on said carrier member with a portion of the panel so asto secure said carrier member over the orifice.
 13. The method of claim8, further comprising the step of engaging an attachment member on saidcarrier member with a portion of the panel so as to secure said carriermember over the orifice.
 14. A physical barrier for sealing an orificein a panel member, comprising: a carrier configured to cover the orificewhen installed; a plurality of locating pins extending from said carrierand configured to extend into the orifice when said carrier is installedso as to maintain said carrier substantially centered over the orifice;at least one attachment member mounted to said carrier, which isphysically distinct from said locating pins, configured to secure saidcarrier over the orifice when installed into the orifice; and a sealingmaterial on said carrier configured to seal an interface between saidcarrier and the panel member when said carrier is installed.